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Operation & Maintenance Instruction August, 2003 Page 1 of 24 4225-50, S.6 NOTE: The following description and operation is based on this device and its components being new or this device and its components having been repaired, tested, installed and maintained in accordance with instructions issued by this and any other applicable Wabtec Corporation publications. WARNING: At the time any part is replaced in this device, the operation of the complete device must pass a series of tests prescribed in the latest issue of the applicable Wabtec Test Specification. At the time this device is applied to the brake equipment arrangement, a stationary vehicle test must be made to ensure that this device functions properly in the total brake equipment arrangement. (Consult your local Wabtec Corporation Representative for identity of the test specification, with latest revision date, that covers this device.) IMPORTANT: Only Wabtec Corporation supplied parts are to be used in the repair of this device in order to obtain satisfactory operation. Commercially available non-O.E.M. parts are unacceptable. NOTE: The part numbers and their associated descriptions are the property of Wabtec Corporation and may not be replicated in any manner or form without the prior sole written consent of an Officer of Wabtec Corporation. ABDX -SS CONTROL VALVE, PART NO. 664742 ABDX -SS ALUMINUM SERVICE PORTION ABDX -SS ALUMINUM EMERGENCY PORTION AUGUST, 2003 fi Registered Trademark of Wabtec Corporation ' 2003 WABCO Freight Car Products. A Wabtec Company. All rights reserved IMPORTANT: This valve is NOT to be applied to freight cars that are assigned to Interchange Service on the North America Continent Railroads.

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4225-50 s64225-50, S.6
NOTE: The following description and operation is based on this device and its components being new or this device and its components having been repaired, tested, installed and maintained in accordance with instructions issued by this and any other applicable Wabtec Corporation publications.
WARNING: At the time any part is replaced in this device, the operation of the complete device must pass a series of tests prescribed in the latest issue of the applicable Wabtec Test Specification. At the time this device is applied to the brake equipment arrangement, a stationary vehicle test must be made to ensure that this device functions properly in the total brake equipment arrangement. (Consult your local Wabtec Corporation Representative for identity of the test specification, with latest revision date, that covers this device.)
IMPORTANT: Only Wabtec Corporation supplied parts are to be used in the repair of this device in order to obtain satisfactory operation. Commercially available non-O.E.M. parts are unacceptable.
NOTE: The part numbers and their associated descriptions are the property of Wabtec Corporation and may not be replicated in any manner or form without the prior sole written consent of an Officer of Wabtec Corporation.
ABDX®-SS CONTROL VALVE, PART NO. 664742
ABDX®-SS ALUMINUM SERVICE PORTION ABDX®-SS ALUMINUM EMERGENCY PORTION
AUGUST, 2003
® Registered Trademark of Wabtec Corporation © 2003 WABCO Freight Car Products. A Wabtec Company. All rights reserved
IMPORTANT: This valve is NOT to be applied to freight cars that are assigned to Interchange Service on the North America Continent Railroads.
Operation & Maintenance Instruction
4225-50, S.6
1.0 DESCRIPTION
The AB Single Capacity Freight Car Air Brake Equipment with the ABDX Type Control Valve is functionally compatible with equipments using the AB, ABD or the ABDW Control Valve. Correct style of ABDX Control Valve must be applied to specific length cars.
The ABDX Type Control Valve improves service braking by providing both a shorter response time and a shorter brake cylinder pressure build up time. The initial quick service function has been improved through a new service piston, diaphragm and diaphragm clamping arrangement.
Other benefits of the ABDX Type Control Valve include improved undesired emergency (UDE) protection, improved protection against leakage, and the elimination of the need for auxiliary continuous quick service valves.
1.1 PARTS OF THE EQUIPMENT
The following is a description of the Control Valve which is part of the AB Freight Car Air Brake Equipment with the ABDX Type Control Valve:
1.1.1 ABDX TYPE CONTROL VALVE
The ABDX Type Control Valve controls the flow of air to and from the brake cylinder and to charge the reservoirs. It consists of a Pipe Bracket, a Service Portion and an Emergency Portion.
1.1.2 PIPE BRACKET
The ABDX Control Valve uses the AAR AB type pipe bracket. This is a two-face pipe bracket to which are mounted the service and emergency portions. Figures 2 and 3 show the port identification on each face. The pipe bracket is semi- permanently bolted to the car. Pipe connections may be made by means of adjustable welded fittings secured to machined flange pads on the pipe bracket. No pipe connections need to be disturbed when removing or replacing the service or emergency portion. The pipe bracket contains the quick action chamber and a removable strainer which provides long life by minimizing the passage of dirt particles to the valve and brake cylinder.
Pipe Connections - Figure 4 shows the pipe bracket face to which the pipe connections are made. Each port connection is identified by number and name.
Figure 1 - Diagrammatic View
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Figure 4 - Pipe Bracket Face Pipe Connections
e3
b
b4
c
EX
a
E2
b
Port a - To Auxillary Reservoir b - To Brake Pipe b2 - To Strainer Nut Cavity c3 - To Emergency Face and Branches c2 and c4 c4 - To Passage c3 e2 - To Emergency Reservoir and to Emergency Face EX - To Retaining Valve
Port b - To Brake Pipe b4 - To Brake Pipe Passage b c - To Brake Cylinder c2 - To Passage c3 c3 - To Service Face and Branch Ports c2 and c4 e3 - To Emergency Reservoir and Service Face Q.A.C. - To Quick Action Chamber
Port Designation Flange Size
1 Brake Pipe 1 inch 2 Emergency Reservoir 3/4 inch 3 Brake Cylinder 3/4 inch 5 Auxiliary Reservoir 3/4 inch
10 Retainer 3/8 inch
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1.1.3 SERVICE PORTION
The Service Portion controls the flow of air from the auxiliary reservoir to the brake cylinder during a service application and the recharging of the auxiliary and emergency reservoirs, and exhaust of brake cylinder during a release. The accelerated release feature speeds up the recharge of brake pipe during a release of a service application by the use of a small amount of air from the emergency reservoir. The Service Portion also includes a large capacity manual release valve. This release valve offers the choice of exhausting only the brake cylinder, exhausting the auxiliary reservoir and brake cylinder, or exhausting both reservoirs and the brake cylinder. Figure 2 shows the port identification on the service portion bolting face. The ABDX-SS Service Portion has been tuned to optimize the Quick Service function for short cars.
1.1.4 EMERGENCY PORTION
The Emergency Portion controls the flow of air from both reservoirs to the brake cylinder during an emergency application. An emergency application can be obtained at any time regardless of the existing state of service application or release, provided brake pipe pressure has not been reduced below 45 psi prior to initiating an emergency. Emergency brake cylinder air pressure is approximately 20% higher than that obtained from a full service brake application. The emergency brake cylinder pressure is developed in two stages, thus reducing train slack action.
The Emergency Portion also contains the accelerated application feature which accelerates the service buildup of brake cylinder pressure throughout the train by locally venting brake pipe at each car. The ABDX-SS Emergency Portion is tuned to optimize this feature on short cars with less than 45 feet of brake pipe.
The emergency accelerated release feature speeds up the recharge of brake pipe during a release of emergency application by the use of air from the brake cylinder and auxiliary reservoir.
2.0 OPERATION
Refer to Wabtec Publication 5062-19 for the operation of ABDX-SS Control Valve.
3.0 MAINTENANCE SCHEDULE
IMPORTANT: The ABDX-SS Control Valve should be removed from the equipment arrangement, taken to the shop, be completely disassembled, the parts cleaned, lubricated, assembled, using NEW Wabtec Corporation rubber parts and other specified NEW Wabtec Corporation parts. The valve is then tested according to the following vehicle application schedule, or more frequently if service conditions so indicate.
RECOMMENDED FREQUENCY AT LEAST TYPE OF APPLICATION ONCE EVERY
FREIGHT Not to exceed 12 YEARS
4.0 PARTS CATALOG INFORMATION
4.1 PARTS CATALOG
IMPORTANT: When ordering replacement parts for the ABDX-SS Control Valve, Part No. 664742, or any of its component portions, refer to the current issue of Wabtec Corporation Parts Catalog 3225-50, S.6.
NOTE: The reference numbers used in this publication and those used in the parts catalog may differ. Check the descriptive parts name to be sure that the desired part is ordered.
4.2 REPLACEMENT PARTS
IMPORTANT: To obtain satisfactory operation and reliability of the ABDX-SS Control Valve, ONLY Wabtec Corporation replacement parts are to be used in the maintenance of the ABDX-SS Control Valve. Commercially available parts are unacceptable.
5.0 SAFETY PROCEDURES & WARNINGS
Regular car builder and/or owner-operating property and/or shop safety procedures MUST BE followed when performing any work on the ABDX-SS Control Valve and/or its component parts.
The work area should be clean.
Operation & Maintenance Instruction
4225-50, S.6
WARNING: The following statements of warning apply, all or in part, wherever the symbol appears in the maintenance procedures. Failure to observe these precautions may result in serious injury to those performing the work and/or bystanders.
Portions weigh in excess of 30 pounds. Use care when lifting and hauling portions to preclude injury.
Due to the possibility of exhausting air, and high decibel levels of noise associated with it, from the device during testing, it is recommended that sufficient hearing and eye protection be used. This is intended to minimize the possibilities of hearing and eye injury to the operator or persons near the test rack.
The use of an air jet, which must be less than 30 p.s.i.g., to blow parts clean or to blow them dry after being cleaned with a solvent will cause particles of dirt and/or droplets of the cleaning solvent to be airborne. Wire brushing may also cause particles of dirt, rust and scale to become airborne. These conditions may cause skin and/or eye irritation.
When using an air jet, do not direct it toward another person. Improper use of air jet could result in bodily injury.
Personal eye protection must be worn when performing any work on this device or its component parts to avoid any possible injury to the eyes.
The use of solvents and lubricants can involve health and/or safety hazards. The manufacturers of the solvents and lubricants should be contacted for safety data (such as OSHA Form OSHA-20 or its equivalent). The recommended precautions and procedures of the manufacturers should be followed.
When performing any test or work on devices or equipment while they are on the vehicle (on car test etc.) special precautions must be taken to ensure that vehicle movement will not occur which could result in injury to personnel and/or damage to equipment.
Figure 5 - ABDX-SS Control Valve, Part No. 664742
8
A
B
3
4
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When performing the procedures which follow, springs within the assembly may be under load. Exercise care so that no parts are inadvertently expelled. Inadvertently expelled parts may cause bodily injury, and/or damage to parts.
All air supply to this device and/or to any component part must be cut off and any air in the device be allowed to vent before this device and/or any component part is removed from the equipment arrangement.
Bottled up air under pressure (even though air supply is cut off) may cause gaskets and/or particles of dirt to become airborne and an increase in sound level when this device and/or any component part is removed from the equipment arrangement. Personal eye and ear protection must be worn and care taken to avoid possible injury when performing any work on this device and/or component part.
An adequate support or lifting device must be available to support the device and/or valve portion(s) during removal, installation and maintenance procedures.
6.0 CLEANING SOLVENT, LUBRICANT & SEALANT
6.1 CLEANING SOLVENT
6.1.1 The means used to clean the reusable parts of the ABDX-SS Type Control Valves MUST BE an aliphatic hydrocarbon solvent, such as mineral spirits or naptha, or a heated aqueous biodegradable detergent and rinse.
IMPORTANT: Cleaning materials are to be used in a well ventilated area.
6.2 LUBRICANT
Brake Cylinder Lubricant M-914
6.2.1 The o-ring, o-ring grooves and the o-ring bearing surfaces of the bushing(s) must be lubricated with Number 2 Silicone Grease, Wabtec Corporation Specification M-07680- 02 (Industry Designation MIL-G-4343), such as Dow Corning Corporation, Dow Corning 55.
6.2.2 The threads of choke plugs and all other removable plugs, as well as all other threaded parts which may later be difficult to remove, must be pre-coated with a Loctite product called Vibraseal #517. The Vibraseal plugs are to be fully threaded into place, however discretion should be used when tightening the choke plug, to facilitate removal.
6.3 SEALANT
6.3.1 Locking Sealant, Westinghouse Air Brake Company Specification M-07499-05, such as Loctite Corporation TL- 242, is required for application to certain threads.
7.0 MAINTENANCE PROCEDURE
7.1 ON-CAR MAINTENANCE PROCEDURES
IMPORTANT: ON-CAR Maintenance is limited to the removal and replacement of Component Portions. No ON- CAR repair of the valve is to be attempted.
7.1.2 SPECIAL TOOLS
IMPORTANT: The information shown in Figures 6 thru 11, for making tools, is furnished as a convenience. The Wabtec Corporation shall have NO responsibility for tools which they do not manufacture and will not be responsible for the results when using any of the specified tools (including claims by third parties).
7.2 PORTION REMOVAL & INSTALLATION - "ON CAR"
7.2.1 IMPORTANT: ALL car builder and owner- operating property safety procedures, in addition to warnings as listed in Section 5 of this publication, MUST BE adhered to.
7.2.2 IMPORTANT: The handbrake(s) of the car MUST BE applied and the wheels of the car chocked to prevent unintentional car movement. Warning placards indicating that work is being performed are to be placed on and about the car.
7.2.3 IMPORTANT: ALL air flow to the ABDX-SS Control Valve MUST BE allowed to deplete and subsequently be cut off.
Operation & Maintenance Instruction
4225-50, S.6
Figure 8 - Service Piston Assembly Fixture
Figure 6 - Hand Tool for Diaphragm Installation Figure 7 - Mandrel for Installing O-rings
Piston or Spool Valve

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Figure 9 - Limiting Valve Piston Spanner Wrench Figure 10 - Service Accelerated Release Valve Piston Spanner Wrench
No. 23 (0.154) Drill (2
Holes)
Pin (2 Reqd) Press in Place

Figure 11 - Inshot Piston Spanner Wrench
11/4
Steel Dowel Pin (2 Reqd)
Press in Place
5 Material: Steel
Break Corners and Remove Burrs To Be Manufactured By Customer
5/8
Material: Steel
7/16 Drill
3/4
4225-50, S.6
7.2.4 Emergency Portion Removal and Installation See Figure 5
7.2.4.1 Scrape, wipe and blow off with a jet of low pressure air (less than 30 psi) all dirt adjacent to the gasket between the pipe bracket and emergency valve portion. Using the blower hose, blow off the emergency portion, pipe bracket hopper slopes, car under frames, etc., to free them of all loose dirt that may otherwise get into the emergency portion or pipe bracket when the portion is being removed and reapplied.
7.2.4.2 Remove the vent protector from the failed emergency portion and apply a WABCO Freight Car Products standard vent protector plug, as shown in Figure 17.
7.2.4.3 The cleaned emergency portion must be handled with care to avoid entrance of dirt or water which could damage the internal parts.
IMPORTANT: The shipping cover must not be removed from the clean replacement emergency portion until it is ready to be mounted to the pipe bracket on the car.
7.2.4.4 Remove the Emergency Portion (1) from the Pipe Bracket Portion (7) by first removing the three 5/8 hex nuts (8) and apply a shipping cover, as shown in Figure 15, and tighten nuts.
7.2.4.5 Remove and SCRAP the Emergency Portion Mounting Gasket (2) from the mounting face of the Pipe Bracket (7).
7.2.4.6 Visually inspect the Pipe Bracket Portion (7) for damage. This portion need not be removed from the equipment arrangement unless it is damaged. If it is necessary to remove the Pipe Bracket Portion (7), car builder and owner-operating property instructions are to be followed.
7.2.4.7 Inspect the Emergency Portion mounting face of the Pipe Bracket Portion (7) to be sure that it is clean and is not damaged or scratched. Be sure that ALL parts are clean and unrestricted. If necessary, the ports can be blown out with a low pressure jet of clean dry air. Exercise care so that no dirt is blown into the ports or passages of the Pipe Bracket Portion (7).
7.2.4.8 Apply a NEW WABCO Freight Car Products Emergency Portion Mounting Gasket (2) to the Pipe Bracket (7).
7.2.4.9 Remove the Vent Protector Plug from the new or satisfactorily repaired and tested Emergency Portion (1). Install a cleaned or renewed Vent Protector into the new Emergency Portion (1).
WARNING: The ABDX-SS portions must not be applied to cars exceeding 39 feet in length. Such incorrect application may result in undesired brake action that could cause equipment damage and injury to bystanders.
7.2.4.10 Remove the shipping cover from the new or satisfactorily repaired and tested Emergency Portion (1) and immediately apply the Emergency Portion (1) to the Pipe Bracket (7). Coat the threads of the mounting studs lightly with brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification [M- 07695-02] (AAR Specification M-913), and two parts oil (SAE- 20) by weight.
7.2.4.11 Tighten the three 5/8 hex nuts (8) evenly and firmly in order to sufficiently prevent gasket leakage and yet not excessively to cause distortion of the mounting gasket (2).
7.2.4.12 After the Emergency Portion (1) has been reinstalled and all repairs have been completed, the entire air brake equipment must be tested in accordance with the latest issue of the Code of Air Brake System Tests for Freight Equipment T-664742A/B-O.
7.2.5 Service Portion Removal and Installation See Figure 5
7.2.5.1 Disconnect the release valve handle or handles, leaving it attached to the release rod or rods.
7.2.5.2 Scrape, wipe and blow off with a jet of low pressure air (less than 30 psi) all dirt adjacent to the gasket between the Pipe Bracket (7) and Service Portion (3). Using the blower hose, blow off the Service Portion (3), Pipe Bracket (7), hopper slopes, car underframe, etc., to free them of all loose dirt that may otherwise get into the Service Portion or Pipe Bracket when the portion is being removed and reapplied.
7.2.5.3 The cleaned Service Portion (3) must be handled with care to avoid entrance of dirt or water which could damage the internal parts.
Operation & Maintenance Instruction
4225-50, S.6
7.2.5.4 IMPORTANT: The shipping cover must not be removed from the clean replacement Service Portion until it is ready to be mounted to the Pipe Bracket on the car.
7.2.5.5 Remove the failed Service Portion (3) and apply the shipping cover and tighten nuts.
7.2.5.6 Apply standard or alternate stem guard (See Figure 16) to the removed Service Portion and hold in place with cotter pin.
7.2.5.7 Remove Service Portion Mounting Gasket (4) and discard properly.
7.2.5.8 Remove the strainer nut (5) using strainer nut wrench then remove and discard the old air strainer (6).
7.2.5.9 Install a NEW air strainer (6). A wooden mandrel of suitable form will assist in guiding the strainer into proper position. Make certain its inner end is in engagement with the sealing bead (if inserted properly, all nut threads will be visible), then insert strainer nut (5) and tighten it firmly using the strainer nut wrench.
7.2.5.10 Install a NEW Service Portion Mounting Gasket (4).
WARNING: The ABDX-SS portions must not be applied to cars exceeding 39 feet in length. Such incorrect application may result in undesired brake action that could cause equipment damage and injury to bystanders.
7.2.5.11 Remove the shipping cover from the new or satisfactorily repaired and tested Service Portion (3) and immediately apply the portion to the Pipe Bracket (7). Coat the threads of the mounting studs lightly with brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M-07695-02 (AAR Specification M-913), and two parts oil (SAE-20) by weight.
7.2.5.12 Tighten the three 5/8 hex nuts (8) evenly and firmly in order to sufficiently prevent gasket leakage and yet not excessively to cause distortion of Mounting Gasket (4).
7.2.5.13 Remove release valve stem guard from the new or repaired service portion and reconnect the release valve handle or handles (which has been left attached to release rod) to release valve handle end plate with a new cotter pin.
7.2.5.14 After the Service Portion has been reinstalled and all repairs have been completed, the entire air brake equipment must be tested in accordance with the latest issue of the Code of Air Brake System Tests for Freight Equipment T-664742A/B-O.
7.3 "IN-SHOP" MAINTENANCE PROCEDURES
IMPORTANT: The procedures which follow are to be performed in the repair shop. To obtain satisfactory operation and reliability of this device only replacement parts supplied by Wabtec Corporation are to be used in the maintenance of this device.
IMPORTANT: When performing the procedures which follow, DO NOT use hard or sharp metal tools to remove gaskets, o-rings, the dust boot, or diaphragm. Exercise care so that no damage is done to parts.
WARNING: When performing the procedures which follow, springs within the assembly may be under load. Exercise care so that no parts are inadvertently expelled. Inadvertently expelled parts may cause bodily injury, and/or damage to parts.
7.4 DISASSEMBLY of ABDX-SS EMERGENCY PORTION See Figure 12
7.4.1 Remove the vent protector assembly from the emergency portion body (58) if it is still in place. The vent protector assembly is not illustrated in Figure 12.
7.4.2 Small Vent Valve Piston, Inshot Check Valve
7.4.3 Depress the spring retainer (28) into the body (58) and tilt it so that it is free of the retaining lip in the body (58) and remove the retainer (28), vent valve spring (29), and the small vent valve (23) from the body (58).
7.4.4 Depress the spring retainer (25) into the body (58) and tilt it so that it is free of the retaining lip in the body (58) and remove the retainer (25), inshot check valve spring (26), and the check valve (27) from the body (58). SCRAP the check valve (27).
7.4.5 Emergency Diaphragm Piston, High Pressure Spool, Emergency Accelerated Release Check Valve
Operation & Maintenance Instruction
4225-50, S.6
1
3
4
5
10
11
27
76
4225-50, S.6
7.4.6 Remove the four 1/2" x 13/4" hex head screws (1) which secure the top cover (2) to the body (58). Remove the cover (2).
7.4.7 Remove and SCRAP the ring gaskets (22, 23, 24) from the top cover (2).
NOTE: The thimble type air strainer (21) can be removed by first removing the retaining ring (20) from the body (58).
7.4.8 Remove the emergency accelerated release check valve spring (17), check valve spring seat (18), emergency accelerated release check valve (19), retaining ring (20), and the thimble type air strainer (21) from the body (58). SCRAP the check valve (19).
7.4.9 Remove the high pressure spool valve return spring (13) and the high pressure spool valve with o-rings (16, 15) from the body (58).
NOTE: For easier removal, thread a 3/8-16 cap screw into the high pressure spool.
7.4.10 Remove and SCRAP the five 13/16" O.D. o-rings (15) from the high pressure valve (16).
7.4.11 Carefully remove the emergency diaphragm piston assembly (3 to 12) as a unit from the body (58).
7.4.12 Carefully drift the 3/32" x 3/4" cylindrical spring pin (6) from the emergency slide valve (8). Remove the emergency slide valve (8), filter (9), and spring (7) from the emergency piston (10).
7.4.13 Remove the 5/8" x 1" hex head cap screw (3) that secures the diaphragm follower (4) and diaphragm (5) to the emergency piston (10). Remove follower (4) and diaphragm (5) from the piston (10). SCRAP the diaphragm (5).
7.4.14 Remove and SCRAP the two emergency wear rings (11 and 12) from the emergency piston (10).
7.4.15 Vent Valve, Inshot Piston, Emergency Accelerated Release Spool
7.4.16 Remove the two 1/2 x 11/8 hex head cap screws (31) and the 1/2 x 13/4 hex head cap screw (32) that secures the vent valve cover (33) to the body (58).
7.4.17 Remove the inshot piston spring (38) and the inshot piston assembly (39 to 43) from the body (58).
7.4.18 Remove and SCRAP the 15/16" O.D. ring gasket (34) and the 5/8" O.D. ring gasket (35) from the vent valve cover (33).
7.4.19 Remove and SCRAP the 3/8" O.D. o-ring (40) from the inshot piston (41).
7.4.20 Use the inshot piston spanner wrench, as shown in Figure 9, to hold the inshot piston (43), then remove the 3/8" self-locking hex nut (39) from the piston (43). SCRAP the nut (39).
7.4.21 Remove the diaphragm follower (40) and diaphragm (41) from the piston (43). SCRAP the diaphragm (41).
7.4.22 Remove the vent valve piston diaphragm (36) and the vent valve piston (37) from the body (58). SCRAP the diaphragm (36).
WARNING: The cap nut (45) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Inadvertently expelled parts may cause bodily injury.
7.4.23 Using a 7/8" square wrench, remove the cap nut with o-ring (45, 44), which secures the emergency accelerated release spool valve spring (46) and emergency accelerated release spool valve (48) with o-rings (47) in the body (58).
7.4.24 Remove the emergency accelerated release spool valve spring (46) and emergency accelerated release spool valve (48) with o-rings (47) from the bottom of the body (56).
7.4.25 Remove and SCRAP the four 11/2" O.D. o-rings (47) from the spool valve (48).
7.4.26 Remove and SCRAP the 11/2" O.D. o-ring (44) from the cap nut (45).
7.5 ASSEMBLY of ABDX-SS EMERGENCY PORTION See Figure 12
7.5.1 Emergency Diaphragm Piston, High Pressure Spool, Emergency Accelerated Release Check Valve
Operation & Maintenance Instruction
4225-50, S.6
7.5.2 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, coat the surfaces of four NEW 11/2" O.D. o-rings (47). Also, lightly lubricate the o-ring grooves of the emergency accelerated release spool valve (48) and the spool valve bushing surfaces of the body (58).
7.5.3 Install the four NEW, lubricated 11/2" O.D. o-rings (47) into their grooves on the emergency accelerated release spool valve (48).
7.5.4 Install the emergency accelerated release spool valve (48) with o-rings (47) into its bush in the body (58), closed end first.
7.5.5 Install the emergency accelerated release spool valve spring (46) into the spool valve (48).
7.5.6 Apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the surfaces of a NEW 11/2" O.D. o-ring (44) and lightly lubricate the o-ring groove of the cap nut (45).
7.5.7 Install the NEW lubricated 11/2" O.D. o-ring (44) into its groove on the cap nut (45).
7.5.8 Install the cap nut with o-ring (45 & 44) into the body (58) to secure the spring (46) and accelerated release spool valve (48) with o-rings (47) in place. Using a 7/8" square wrench, tighten the cap nut (45) between 55 and 65 foot-pounds of torque.
7.5.9 Install the emergency wear rings (11 & 12) on the emergency piston (10).
IMPORTANT: Care should be taken when expanding or opening the wear rings during installation onto the emergency piston. Do not overexpand the rings causing them to deform which would result in difficult installation of the piston into the bore. The protective ring should be installed with the gap facing the slide valve area of the emergency piston. The positioning of the rings will ease the assembly.
7.5.10 Install a NEW emergency piston diaphragm (5) on the emergency piston (10) so that the piece number on the diaphragm is facing away from the piston.
7.5.11 Lightly coat the threads of the 5/8" x 1" hex head screw (3) with LOCTITE Sealant TL-242, Wabtec Corporation Specification M-07499-05. Install the cap screw (3) through the diaphragm follower (4) and into the piston (10) to secure
the piston (10), diaphragm (5) and follower (4) together. Hand tighten the cap screw (3) and flip the diaphragm (5) in the opposite direction so that the large cone shaped opening is facing the piston (10). Torque the screw (3) between 45 and 50 foot-pounds.
7.5.12 Insert the emergency slide valve spring (7) into the emergency slide valve (8).
7.5.13 Carefully place the emergency slide valve with spring (8 & 7) on the stem of the piston (10) and secure the parts in place by installing the 3/32" x 3/4" cylindrical spring pin (6).
7.5.14 Using a foam-tipped applicator, evenly spread a light coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20, (AAR Specification M-912) over the face of the emergency slide valve (8).
7.5.15 Evenly spread a light coating of the Triple Valve Oil on the slide valve bushing seat of the body (58).
7.5.16 Evenly spread a light coating of Triple Valve Oil over the guide portion of the stem and piston end of the piston (10).
IMPORTANT: Care must be taken when compressing the slide valve spring (7) in preparation for inserting the emergency piston assembly (3 to 10) into the body bushing. While using minimal force, the assembly must be aligned squarely to prevent any wedging or distortion. The slide valve face (8) must be retracted from the bushing face as long as possible.
7.5.17 Install the diaphragm - piston - emergency slide valve assembly (3 to 10) into the body (58). Exercise care so that NO damage is done to the emergency slide valve bushing seat.
7.5.18 Using the pressure of the thumb or finger, position the sealing bead of the diaphragm in the diaphragm bead groove of the body (58).
7.5.19 Coat the surfaces of five NEW 13/16" O.D. o-rings (15) with #2 Silicone Grease, Wabtec Corporation Specification M-07680-02. Also lightly lubricate the o-ring grooves of the high pressure spool valve (16) and the bearing surfaces of the spool valve bushing of the body (58).
7.5.20 Install the five NEW lubricated 13/16" O.D. o-rings (15) into their grooves on the high pressure spool valve (16).
Operation & Maintenance Instruction
4225-50, S.6
7.5.21 Install the high pressure spool valve with o-rings (16, 15) into the body (58).
7.5.22 Install the high pressure spool valve return spring (13) into the high pressure spool valve (16).
7.5.23 Install a NEW thimble type air strainer (21) into the emergency accelerated check valve seat of the body (58). Secure the thimble type air strainer (21) into the body (58) with the retaining ring (20).
7.5.24 Install a NEW emergency accelerated release check valve (19) and check valve spring seat (18) and the check valve spring (17) into the body (58).
7.5.25 Install a NEW 13/4" O.D. ring gasket (22), two NEW 11/2" O.D. ring gaskets (23) and a NEW 11/8" O.D. ring gasket (24) into their grooves in the top cover (2).
7.5.26 Place the top cover assembly (2) with ring gaskets (22, 23, 24) on the body (58) making sure that the diaphragm (5) and ring gaskets (22, 23, 24) remain in position.
7.5.27 Secure the cover (2) to the body (58) by installing the four 1/2" x 13/4" hex head screws (1). Torque the screws between 35 and 55 foot-pounds.
7.5.28 Vent Valve, Inshot Piston, Emergency Accelerated Release Spool
7.5.29 Install a NEW inshot diaphragm (41) on the inshot piston (43) so that the flat surface of the diaphragm which shows the part number faces away from the piston.
7.5.30 Install the diaphragm follower (40) on the piston (43) so that the small diameter of the follower (40) is facing the diaphragm (41). Secure the follower (40) and the diaphragm (41) on the inshot piston (43) by installing a NEW 3/8-16 self- locking hex nut (39). Torque the nut to 9 to 12 foot-pounds.
7.5.31 Apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the surfaces of a NEW 3/8" O.D. o-ring (42). Also lightly lubricate the O-ring groove on the shaft of the inshot piston (43) and the bearing surfaces of the inshot piston bushing of the body (58).
7.5.32 Install the NEW lubricated 3/8" O.D. o-ring (42) into its groove on the shaft of the inshot piston (43).
7.5.33 Install the inshot diaphragm piston assembly (39 to 43) into the body (58). Be sure that the bead of the diaphragm (41) is properly seated in the bead groove of the body (58).
7.5.34 Install the inshot piston spring (38) over the nut (39) on the exposed end of the inshot piston (43) so that the spring seats in the diaphragm follower (40).
7.5.35 Using a foam-tipped swab applicator, evenly spread a light coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20 (AAR Specification M-912), to the large diameter surface of the stem of the vent valve piston (37). Carefully insert the vent valve piston (37) into the body (58).
7.5.36 Place a NEW vent valve piston diaphragm (36) on the vent valve piston (37) ensuring that the part number on the diaphragm faces the piston. With the aid of the hand tool, shown in Figure 6, properly position the diaphragm (36) so that the loop of the diaphragm sits between the piston (37) and body (58).
7.5.37 Install a NEW 15/16" O.D. ring gasket (34) and a NEW 5/8" O.D. ring gasket (35) in their grooves in the vent valve cover (33).
7.5.38 Place the vent valve cover (33) on the body (58) and install the two 1/2 x 11/8 hex head screws (31), the METAL IDENTIFICATION TAG (29a), and the 1/2 x 13/4 hex head cap screw (32).
7.5.39 Small Vent Valve, Inshot Check Valve
7.5.40 Install a NEW inshot check valve (27) and the inshot check valve spring (26) into the body (58). Align properly and secure these parts in place by installing the inshot spring retainer (25).
7.5.41 Using a foam-tipped swab applicator, evenly spread a light coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20 (AAR Specification M-912), to the outer diameter surfaces of the small vent valve piston (30). Install the small vent valve piston assembly (30) seal end first, into the body (58).
7.5.42 Install the small vent valve piston spring (29) into the small vent valve (30) and secure it in place by installing the spring retainer (28) in the body (58). Be sure that the retainer (28) is properly secured.
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7.6 DISASSEMBLY of ABDX-SS SERVICE PORTION See Figures 13 & 14
7.6.1 Remove the release valve portion (54) from the body (49) by first removing the three 3/8" flanged hex nuts (52).
7.6.2 Remove and SCRAP the five 13/16" O.D. ring gaskets (56) and the 7/8" O.D. ring gasket (55) from the mounting face of the release valve portion (54). Remove the wire mesh strainers (57) from the body (49).
7.6.3 Set the release valve portion (54) aside in a clean, protected area for later disassembly.
7.6.4 Service Diaphragm Piston
7.6.5 Remove the top cover (2) from the body (49) by removing the four 1/2" x 13/4" hex head screws (1).
7.6.6 Remove and SCRAP the 11/16" O.D. ring gasket (3) from the top cover (2).
7.6.7 Carefully remove the service piston assembly (4 to 17) as a unit from the body (49).
7.6.8 Place the service piston assembly (4 to 17) on the Service Piston Assembly fixture, Part No. 564522 as shown in Figure 8. Hold the service piston assembly in position so that the slide valve spring (13) rests on the fixture with the seat of the slide valve (15) facing upward.
7.6.9 Using the driver pin that is furnished with the piston holding fixture, carefully drift the 3/32" x 1" cylindrical spring pin (11) from the slide valve (15).
7.6.10 Remove the slide valve spring (12), slide valve (15), graduating valve (14) and graduating valve spring (13) from the service piston (16).
7.6.11 Remove the 5/8" x 1" hex head cap screw (4) which secures the diaphragm follower (5) and diaphragm (6) to the service piston (17).
7.6.12 Remove the diaphragm follower (5) and diaphragm (6) from the service piston (16). SCRAP the diaphragm (6).
7.6.13 Remove the spring seat retaining ring (7) from the tail of the service piston (16), then remove the spring seat (8), spring (9) and spring guide (10). Remove and SCRAP the service piston rings (17) from the service piston (16).
7.6.14 Limiting Valve, Back Flow Check Valve
7.6.15 Remove the four 1/2" x 11/4" hex head screws (33) which secure the bottom cover (44) to the body (49).
WARNING: The bottom cover (44) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Inadvertently expelled parts may cause bodily injury.
7.6.16 Remove the bottom cover (34) from the body (49).
7.6.17 Remove and SCRAP the 11/16" O.D. ring gasket (38), the 2" O.D. ring gasket (35) and the 2" flange fitting gasket (39) from the cover (34).
7.6.18 Remove the check valve spring (36) and the check valve (37) from the body (49). SCRAP the check valve (37).
7.6.19 Remove the brake cylinder limiting valve spring (42), diaphragm follower (43) and the brake cylinder limiting valve diaphragm (44) from the body (49).
7.6.20 Remove and SCRAP the o-rings (46 & 47) from the brake cylinder limiting valve stem (45).
7.6.21 Remove the piston return spring (40) and the spring cage (41) from the body (49).
7.6.22 Accelerated Service Release Valve
7.6.23 Remove the service accelerated release valve cover (19), wear protection disk (20), and diaphragm/piston assembly (21 to 24) as a unit from the filling piece (31) by first removing the four 1/2" x 23/4" hex head screws (18).
7.6.24 Remove the service accelerated release valve piston/ diaphragm assembly (21 to 24) from the cover (19).
7.6.25 Using the Service Accelerated Release Valve Piston Spanner Wrench, as shown in Figure 10, to hold the service accelerated release valve piston (24), remove the 9/16" hex head nut (21), diaphragm follower (22) and the diaphragm (23) from the threaded end of the piston (24). SCRAP the diaphragm (23).
NOTE: If required, use a flat bar placed in the slot to retain the service accelerated release piston (24) while removing the 9/16 hex head nut (21).
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7.6.26 Remove the service portion filling piece, plunger, check valve assembly, and mounting gasket (25 to 32) as a unit from the body (49).
7.6.75 Remove and SCRAP the filling piece mounting gasket (32).
7.6.28 Compress and remove the spring seat (28), check valve spring (29), and accelerated release check valve (30) from the filling piece (31). SCRAP the check valve (30).
7.6.29 Remove the service accelerated release valve plunger with o-ring (25, 26) by pushing it out of the cover end of the filling piece (31). Remove and SCRAP the 1/4" O.D. o-ring (26) from the end of the plunger (25).
7.6.30 Remove and SCRAP the 11/16" O.D. ring gasket (27) from its groove in the filling piece.
7.6.31 Retrieve the release valve portion (54) which was previously set aside in a clean, protected area.
7.6.32 Disassembly of Release Valve Portion See Figure 14
7.6.33 Remove the five 3/8" x 11/2" hex head screws (1) which secure the top cover (2) of the release valve portion to the release valve body (35).
7.6.34 Remove the top cover (2) from the body (35).
7.6.35 Remove and SCRAP the two 1" O.D. ring gaskets (3) from their grooves in the top cover (2).
7.6.36 Remove the two check valve springs (12), the auxiliary and emergency reservoir check valves (13) and the two check valve plungers (14) from the body (35). SCRAP the two check valves (13).
7.6.37 Remove the spool valve spring (4) from the body (35).
7.6.38 Remove the spool valve - diaphragm follower - diaphragm assembly (5 to 11) from the body (35) as a unit.
7.6.39 Remove and SCRAP the three 3/4" O.D. o-rings (11) from their grooves on the spool valve (10).
7.6.40 Using an open end wrench to hold the spool valve (10), remove the 3/8" self-locking nut (5), diaphragm follower
(6), diaphragm (7) and the piston with o-ring (8, 9) from the threaded end of the spool valve (10). Remove the 1/2" O.D. o-ring (9) from its groove in the piston (8). SCRAP the o-ring (9), diaphragm (7) and the self-locking nut (5).
7.6.41 Remove and SCRAP the 3/16" x 2" cotter pin (24) which secures the release valve stem guard (25) to the stem and end plate (27). Remove the stem guard (25).
WARNING: The bottom cover (31) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Accidently expelled parts may cause bodily injury.
7.6.42 Remove the five 3/8" x 13/4" hex head cap screws (15) that secure the bottom cover, valve seal, exhaust seal stem, and end plate assembly (27 to 33) to the body (35). Remove the cover assembly from the body (35).
7.6.43 Remove the stem and end plate (27), bottom cover gasket (28), seal (30) and 5/8" O.D. ring gasket (29) from the cover (31). SCRAP the gaskets (28, 29) and seal (30).
7.6.44 Remove the lifter (26) and lifter spring (23) from the body (35).
7.6.45 Remove the bottom cover sleeve (34) from the bottom cover (31).
7.6.46 Cut off the head of the 3/16" x 1/2" aluminum pop rivet (33) and remove the rivet (33) and seal (32) from the bottom cover (31). SCRAP the rivet (33) and seal (32).
7.6.47 Remove the retaining check valve (20) and its spring (19) from the body (35). SCRAP the check valve (20).
7.6.48 Remove the reset check valve spring (22) and the reset check valve (21) from the body (35). SCRAP the check valve (21).
7.6.49 Remove the reset spool valve with o-ring assembly (18, 17) and the reset spool valve spring (16) from the body (35).
7.6.50 Remove and SCRAP the three 3/4" O.D. o-rings (17) from the reset spool valve (18).
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7.7.1 Service Diaphragm Piston
7.7.2 Install the service piston rings (17) on the service piston (16).
IMPORTANT: Care should be taken when expanding or opening the service piston rings during installation onto the service piston. Do not overexpand the rings causing them to deform which would result in difficult installation of the piston into the bore. The service piston ring should be installed with the gap facing the slide valve area of the service piston. The positioning of the rings will ease the assembly.
7.7.3 Position a NEW diaphragm (6) on the service piston (16) so that the part number on the diaphragm (6) faces away from the piston (16). After positioning the diaphragm bead into the groove of the piston, flip the diaphragm (6) so that the large cone shaped opening is facing the follower (5).
7.7.4 Position the diaphragm follower (5) on the diaphragm (6) and piston (16).
7.7.5 Lightly coat the threads of the 5/8" x 1" hex head cap screw (4) with Loctite Sealant TL-242, Wabtec Corporation Specification M-07499-05. Install the cap screw (4) through the diaphragm follower (5) and into the piston (16) to secure the piston (16), diaphragm (6) and follower (5) together. Hand tighten the cap screw (4) and flip the diaphragm (6) in the opposite direction so that the large cone shaped opening is facing the piston (16). Torque the screw (4) between 45 and 50 foot-pounds.
7.7.6 Using a foam-tipped swab applicator, evenly spread a light coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20 (AAR Specification M-912) around the surfaces of the piston spring guide (10) and the bearing surfaces of the piston bushing.
7.7.7 Install the piston spring guide (10), closed end first, into the open end of the service piston (16).
7.7.8 Install the piston spring (9) and spring seat (8) into the open end of the spring guide (10) and secure the parts in place by installing the spring retainer (7).
7.7.9 Place the slide valve spring (12) on the holding fixture, Part No. 564522, as shown in Figure 8.
7.7.10 Using a foam-tipped swab applicator, evenly spread a light coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20, (AAR Specification M-912) on the face of the graduating valve (14) and over the graduating valve seat of the slide valve (15).
7.7.11 Install the graduating valve spring (13), graduating valve (14), and slide valve (15) on to the piston (16).
7.7.12 Place the piston assembly on the slide valve spring (12) which is still in the holding fixture.
7.7.13 Make sure that the graduating valve (14) is on its seat in the slide valve (15) and that the slide valve side wings are down tight in the fixture.
7.7.14 Install the 3/32" x 1" cylindrical spring pin (11) through the pin holes of each of the wings of the slide valve (15) and the aligned pin hole of the slide valve spring (13). With the aid of the pin driver supplied with the holding fixture, Part No. 564522, secure the pin (11) in place.
7.7.15 Remove the assembly from the holding fixture.
7.7.16 Using a foam-tipped swab applicator, evenly spread a light coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20 (AAR Specification M-912) over the face of the slide valve (15) and the service piston rings (17) on the service piston (16). Also apply a light coating of the Triple Valve Oil to the slide valve seat of its bushing in the body (49), and to the collars and fins of the piston (16) near the piston head.
IMPORTANT: Care must be taken when compressing the graduating valve and slide valve in preparation for inserting the service piston assembly with rings (4 to 17) into the body bushing. While using minimal force, the assembly must be aligned squarely to prevent any wedging or distortion. The slide valve face (15) must be retracted from the bushing face as long as possible. Care must be taken not to damage the slide valve seats.
7.7.17 Install the piston - diaphragm - slide valve assembly (4 to 17) into the body (49) from the top, exercising care so that NO damage is done to the slide valve seat.
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7.7.18 Using only finger and thumb pressure, position the sealing bead of the diaphragm (6) into the diaphragm bead groove on the top cover mounting face of the body (49).
7.7.19 Install a NEW 11/16" O.D. ring gasket (3) into its groove in the top cover (2).
7.7.20 Insert two guide pins into two diagonally opposite threaded holes of the body (49). Using the pins as guides, position the cover assembly (2, 3) onto the body (49). In the remaining two threaded holes, tighten by hand, two 1/2" x 13/4" hex head cap screws (1). Remove the two guide pins and install the other two 1/2" x 13/4" hex head cap screws (1). Torque all four cap screws between 35 and 55 foot-pounds.
7.7.21 Limiting Valve, Back Flow Check Valve
7.7.22 Using a foam-tipped swab applicator, evenly spread a light coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20 (AAR Specification M-912) around the collar on each end of the spring cage (41).
7.7.23 Install the piston return spring (40) into the spring cage (41), then install the cage with spring (41, 40) as a unit into the body (49) so that the spring (40) goes over and around the end of the shaft of the piston (16), which has already been installed.
7.7.24 Position a NEW diaphragm (44) onto the brake cylinder limiting valve stem (45) so that the flat surface of the diaphragm, which shows the part number, faces away from the stem towards the threaded end.
7.7.25 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, lubricate the surfaces of two NEW o-rings (47, 46). Also lightly lubricate the o-ring grooves on the shaft of the stem (45) and the bearing surfaces of the piston bushing in the body (49).
7.7.26 Install the spring, stem and diaphragm (45 to 48) into the body (49), o-ring end first. Be sure that the bead of the diaphragm (44) is properly seated in its groove in the body (49). Use finger pressure to seat the bead.
7.7.27 Install the diaphragm follower (43) and brake cylinder limiting valve spring (42) into the body (49) so that it seats on the diaphragm follower (44).
7.7.28 Install a NEW back flow check valve (37) and the check valve spring (36) into the proper cavity of the body (49).
7.7.29 Install a NEW 2" flange fitting gasket (39), a NEW 2" O.D. ring gasket (35) and a NEW 11/16" O.D. ring gasket (38) into their grooves in the bottom cover (34).
7.7.30 Carefully position the bottom cover assembly (34, 35, 38 and 39) on the body (49) making sure that all gaskets and assemblies of the body are properly in place. Secure the bottom cover (34) to the body (49) by installing four 1/2" x 11/4" hex head screws (33). Equally torque the screws between 35 and 55 foot-pounds.
7.7.31 Accelerated Service Release Valve
7.7.32 Install a NEW accelerated release check valve (30) into the service portion filling piece (31).
7.7.33 Install the check valve spring (29) into the filling piece (31) so that it seats on the check valve (30), then install the spring seat (28) to retain the parts in place.
7.7.34 Place a NEW filling piece gasket (32) and the service portion filling piece (31) in position on the body (49).
7.7.35 Apply a light coating of #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the surfaces of a NEW 1/4" O.D. o-ring (26). Also lightly lubricate the o-ring groove on the service accelerated release valve plunger (25) and the bearing surfaces of the plunger bushing of the filling piece.
7.7.36 Install the NEW lubricated 1/4" O.D. o-ring (26) into its groove on the short end of the service accelerated release valve plunger (25), then install the plunger with o-ring (26, 25) into the filling piece (31), longer end of the plunger first.
7.7.37 Using the Accelerated Release Valve Piston Spanner Wrench, as shown in Figure 10, to hold the service accelerated release valve piston (24), install a NEW diaphragm (23) onto the piston (24) so that the part number on the diaphragm faces away from the piston toward the threaded end.
7.7.38 Install the diaphragm follower (22) and lightly coat the threads of the service accelerated release valve piston
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(24) with Loctite Sealant TL-242, Wabtec Corporation Specification M-07499-05. Install the 9/16" nut (21) on the threaded end of the piston (24) and torque the nut (21) between 40 and 55 foot-pounds.
7.7.39 Install the diaphragm - piston assembly (21 to 24), piston end first into the filling piece (31). Be sure that the bead of the diaphragm is properly seated in its groove on the filling piece (31). Use finger pressure to properly seat the diaphragm bead.
7.7.40 Install the wear protection disk (20) over the hex nut (21). The disc lies on the follower (22) and is not held in place by any means. The body will have to be positioned so the disc remains in place while installing the cover (19).
7.7.41 Install a NEW 11/16" O.D. ring gasket (26) into its groove on the cover mounting face of the filling piece (30).
7.7.42 Place the service accelerated release valve cover (19) in position on the filling piece (30). Be sure that all parts are properly positioned, then using the four 1/2" x 23/4" hex head screws (18), secure the cover and filling piece assemblies (19 to 31) to the body (49). Equally torque the screws (18) between 35 and 55 foot-pounds.
7.7.43 Release Valve Portion Assembly See Figure 8
7.7.44 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, lightly lubricate the surfaces of three NEW 3/4" O.D. o-rings (17). Also lightly lubricate the o-ring grooves of the spool valve (18) and the bearing surfaces of the spool valve bushing of the release valve portion body (35).
7.7.45 Install the three NEW lubricated 3/4" O.D. o-rings (17) into their grooves on the spool valve (18).
7.7.46 Install the spool valve spring (16) and spool valve with o-ring assembly (17, 18) into the release valve body (35).
7.7.47 Install the lifter spring (23) and lifter (26) into the proper cavity in the release valve body (35).
7.7.48 Install a NEW reset check valve (21) and the check valve spring (22) into the proper cavity of the release valve body (35).
7.7.49 Install the check valve spring (19) and a NEW retaining check valve (20) in the proper cavity of the release valve body (35). The seat for the retaining check valve is located in the bottom cover.
7.7.50 Install the bottom cover sleeve (34) and secure a NEW seal (32) with a NEW 3/16" x 1/2" aluminum pop rivet (33) in the bottom cover (31).
7.7.51 Install a NEW valve seal (30), stem and end plate (27), a NEW 5/8" O.D. ring gasket (29) and a NEW bottom cover gasket (28) in place in or on the bottom cover (31).
7.7.52 Carefully position the bottom cover assembly (27 to 34) on the body (35) without applying heavy pressure, then insert the five 3/8" x 13/4" hex head cap screws (15) into the cover (31). Observe the retaining check valve (20) to be sure that it is in alignment with the check valve seat in the cover (31). Also be sure that the reset check valve spring (22) is properly positioned in the cover (31), then hand press the cover (31) to the body (35) and secure it in place by equally tightening the five 3/8" x 13/4" hex head cap screws (15) to a torque value between 15 and 25 foot-pounds.
7.7.53 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, lightly coat the surfaces of a NEW 1/2" O.D. o-ring (9) and three NEW 3/4" O.D. o-rings (11). Also lightly coat the o-ring grooves on the spool valve (10) and the bearing surfaces of the spool valve bushing of the body (35).
7.7.54 Using an open end wrench to hold the spool valve (10), install the piston (8) on the threaded end of the spool valve (10).
7.7.55 Install the NEW lubricated 1/2" O.D. o-ring (9) in place on the piston (8), then install a NEW diaphragm (7) so that the part number on the diaphragm faces away from the piston toward the threaded end of the spool valve (10).
7.7.56 Install the diaphragm follower (6) and a NEW 3/8-16 self-locking hex nut (5) on the threaded end of the spool valve (10). Secure the parts together by torquing the nut (5) to 12 to 14 foot-pounds.
7.7.57 Install the three NEW lubricated 3/4" O.D. o-rings (11) into the three o-ring grooves of the spool valve (10).
7.7.58 Install the diaphragm piston assembly (5 to 11) into the body (35). Be sure that the bead of the diaphragm (7) is
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properly seated in the bead groove of the body (35). Use finger pressure to seat the bead in the groove.
7.7.59 Install the spool valve spring (4) in the body (35) so that it is seated on the diaphragm follower (6).
7.7.60 Install the emergency and auxiliary reservoir check valve plungers (14) into the proper cavities of the body (35).
7.7.61 Install two NEW check valves (13) into the body (35) on top of the two plungers (14), then install the two check valve springs (12).
7.7.62 Install two NEW 1" O.D. ring gaskets (3) into their grooves in the top cover (2).
7.7.63 Carefully place the top cover assembly (2, 3) onto the body (35) being sure that the springs (4 and 12) are properly positioned in the spring cavities of the cover. Secure the top cover (2) to the body (35) by installing the five 3/8" x 11/2" hex head cap screws (1). Equally torque the screws between 15 and 25 foot-pounds.
7.7.64 Install three cleaned wire mesh filter screens (57) in place in the release valve portion body (48).
7.7.65 Install a NEW 7/8" O.D. ring gasket (55) and five NEW 13/16" O.D. ring gaskets (56) into their grooves on the mounting face of the release valve portion (58).
7.7.66 Place the release valve portion (58) on the service portion body (48) and secure it in place by installing three 3/8" flanged hex nuts (53). Equally torque the nuts between 11 and 30 foot-pounds.
7.7.67 The release valve stem guard (25) is to be installed after the service portion has been tested. Use a NEW 3/16 x 2 cotter pin (24) when installing the guard (25).
7.8 CLEANING & INSPECTING
7.8.1 NON-REUSABLE PARTS
IMPORTANT: ALL gaskets, o-rings, self-locking or elastic stop nuts, diaphragms and wear rings ARE TO BE SCRAPPED AND REPLACED WITH NEW WABTEC CORPORATION PARTS.
7.8.2 REUSABLE PARTS
7.8.2.1 Wash ALL reusable parts in the cleaning solvent described in Section 6. Springs may be wire brushed to assist in the removal of any dirt, rust or scale. Care must be taken not to damage springs.
IMPORTANT: Cleaning solvents are to be used in a well ventilated area.
7.8.2.2 The operating portions must be completely dismantled and all parts inspected and cleaned. Parts, including the body interior, must be cleaned by an approved method that will dissolve oil and grease without damage to the parts. The body must not be submerged in a solution. A wire brush may be used to assist in the removal of any light surface dirt, rust or scale on cast parts. The exterior of the body must be thoroughly cleaned.
7.8.2.3 All pistons, slide valves, graduating valves and bushings must be thoroughly cleaned. To do this, the piston, slide valve and graduating valve assembly must be dismantled.
7.8.2.4 After the parts have been cleaned, they MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the parts dry.
8.0 TESTING AND ADDITIONAL INFORMATION
8.1 After the ABDX-SS Control Valve has been assembled, but before it has been returned to service, it must pass a series of tests following the procedures of the current issue of Wabtec Corporation Test Specification T-664742A/B-O.
8.2 IMPORTANT: The ABDX-SS portions are not to be applied to cars exceeding 39 feet in length. Extreme caution musty be taken to ensure the portions replace like portions on the car. Failure to heed these instructions may result in equipment damage and/or personal injury.
8.3 IMPORTANT: When installing the Emergency, Service or both Portions on the ABDX-SS Pipe Bracket Portion, NEW gaskets and filters must be used, see Section 7.2.
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Figure 15 - Shipping Covers
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WABCO Freight Car Products 1001 Air Brake Avenue www.wabtec.com 475 Seaman Street Wilmerding, Pennsylvania 15148 Stoney Creek, Ontario L8E 2R2 (412) 825-1000 Fax (412) 825-1019 (905) 561-8700 Fax (905) 561-8705
8.4 IMPORTANT: Whenever the Emergency or Service Portion is removed from an equipment arrangement, for any reason, and it is reinstalled or replaced with a NEW or REPAIRED and TESTED Portion, the ABDX-SS Control Valve must be tested to ensure that it works properly in conjunction with the remainder of the brake equipment.